Superhydrophobic Surface Coatings Against Corrosion

Andrew K. Jones, Vinod Sikka, Ph.D, Michael Hurley, Ph.D.

June 2011

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Our Experts

Ross Director of Research & Development Dr. Vinod K. Sikka

Manager of Research & Development, Materials Science Division, Oak Ridge National Laboratory (ORNL) Over 43 patents Over 200 publications Inventor of the Year in 2007 (over 4,000 scientists) Scientist of the Year in 2007 1982-2010 14 R&D 100 Awards! 2006 TMS Application to Practice Award ORNL Corporate Fellow ASTM International Fellow Ph.D. in Material Science, University of Cincinnati M.S. in Materials Science, University of Cincinnati B.E. in Metallurgy, Indian Institute of Science, India B.S. in Chemistry, Delhi University, India
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Our Experts

Ross Senior Chemist Dr. Michael F. Hurley

Senior Development Scientist, Polyurethane Division, Bayer Material Science Senior Process Chemist, Mobay Chemical Over 12 patents Over 20 publications Post-Doctoral Scholar, University of Michigan Ph.D. in Organic Chemistry, University of Tennessee B.S. in Chemistry, Fairfield University Applied Rheology and Polymer Processing, Virginia Tech Polymer Chemistry: Principles and Practices, Virginia Tech

June 2011

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Outline

Background Attributes of Ross Coatings Recent Advances in Technology Examples of Coating Application Application Methods In-field Experience Testing Equipment at ROSS for these Coatings

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Hydrophobic/Hydrophillic Contact Angle

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Ross Superhydrophobic Coatings (NeverWet)

Nearly perfect, spherical beads of water shown on
Aluminum-coated surface with NeverWet
Water Bead is Nearly a Perfect Sphere Make a Contact Angle with Surface between 150-180 Water Bead Glides over the Surface like Gliding over Ice

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Superhydrophobic Contact Angles

The contact angles of a Superhydrophobic surface is where the water droplet exceeds 150 and the roll-off angle is less than 10. This is also referred to as the Lotus effect.
Here are the contact angles of water on various surfaces:
June 2011

NeverWet Coatings: 160 to 175

Teflon (cooking pan): 110 Rain-X: 95 Freshly waxed car: 90
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Anti-acid, Alkali, Salts

Aqueous Solutions of Acids, Alkalis, and Salts
Bead Up Similar to Water and Cause No Wetting

Note: Pictures shown for 50% solution magnesium chloride salt.

June 2011

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Anti-Heavy Oils
Ross-coated Surfaces Resist Vegetable Oils, Mineral Oils,
or Any Other Heavy Oils as well as they Resist Water

June 2011

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Anti-Wetting
Ross Coated Panel was Dry after being
Submerged for 12 Months in Seawater

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Anti-Wetting and Breathable Fabric

Ross coating produces a non-wetting and
breathable fabric

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Anti-Corrosion
Ross has demonstrated in Salt-Fog testing that these
coatings survive 4 to 10 times as long as similar coatings without Ross prior to showing any corrosion

NeverWet I Coating after 400 h Technology is Confidential & Proprietary

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Anti-Corrosion
2000 hours of Salt Fog testing on Ross coating
as compared to Polyurethane, an 8x improvement

Polyurethane
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NeverWet

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Anti-Corrosion
In-field exposure of a coated plate after 24 months

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License Plate on Pick-up Truck

(a) 1575 highway (b) (c) (d)
miles 3458 highway plus town miles Oil droplets on SH plate Water droplets on SH plate

Note: Truck was driven at average speeds of 60-62 miles/h with peak speeds of 68 miles. Coating was not affected by those speeds, pouring down rains, and exhaust from other vehicles on the highways.
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Anti-Icing
While no testing has been done on air foils, Ross has
demonstrated numerous other applications (mostly for utilities) where ice will not form on these surfaces

Coated

Uncoated

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Anti-Icing
Antenna dish after a night of freezing rain

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Anti-Icing
Close-up view of the coated dish area

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Anti-Icing
Close-up view of the uncoated dish area

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Anti-Condensation

A Steel Turbine Cascade Coated with Ross Superhydrophobic Coating was Tested in Wind Tunnel at 68 Miles/Hr under Water Condensing Conditions to Simulate Steam Turbine Condensing Conditions

Ross coating was the only one that showed no condensed water film formation as opposed to three other commercial coatings.

June 2011

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Self-Cleaning
While Solids can Set on these
Surfaces, Any Rain or Light Water Almost Always Cleans them Completely (a) Start up cleaning (b) Cleaning in progress (c) Cleaning continues

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Anti-Bacterial
Bacteria are just about everywhere, but they team in impure water, where they have ample food.
NeverWet surfaces are great for: Hospital applications Bathroom applications House siding where mold and fungus grows Very wet environments where bacteria thrive
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Anti-Bacterial
Our first application of NeverWet coatings was with hospital applications (bed pans, toilet plungers, etc), and we did extensive bacterial testing as a part of this process. We tested our surfaces in extremely polluted waters. As virtually no water ever touches our surfaces, virtually no bacteria remain. As a result, these surfaces have proven to be extremely anti-bacterial.

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Anti-Spill
Hydrophilic/hydrophobic combination to dreate spill-proof glass sufrace

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Anti-Spill
Side view showing water height that is possible with hydrophilic/hydrophobic combination

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Anti-Spill
Ross glass border technology is in commercial use through our licensee

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Other Applications
Ross SH coatings in electric motors

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Other Applications

Electrical emergency switches internally coated with Ross SH coating prevent arcing in food processor industry applications
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Note: One switch has been in service for almost one year with no unexpected shutdown.

Other Applications
Ross SH coatings on submerged microelectronics

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Next Generation of Advances in Rub Durability of SH Technology at Ross

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Ross Yields 200X Improvement in Taber Cycles as Opposed to Competitive Data Generated at Ross

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Taber Cycles as a Function of Thickness for NeverWet-NuO SH Coating

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Durable
NeverWet coatings have proven durable through a
variety of tests:
Salt-fog testing (> 1200 hours) Saltwater submersion (> 400 days) Aqueous solutions of acids, alkalis and salts (up to 50%) Extreme temperatures (> 1 year at 450F and transients of 550F) Bending (>120 degree bend after 400F thermal cycle) Drag reduction testing (30% drag reduction for < 10 ft/s) Taber

minimum 500 tabers for 25 micron coating minimum 1100 tabers for 50 micron coating minimum 1750 tabers for 75 micron coating
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Other Attributes
Various color options are possible with Ross
SH/OP Coatings

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Other Attributes
SH Coatings resist
debonding or flaking

Note: Dipped in liquid N2 and bent at room temperature with frequent dips.

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Other Attributes
Aluminum-coated plates
(NeverWet NuO and I) after 1 hour of thermal exposure

NeverWet-NuO

NeverWet-I

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Other Attributes
Aluminum-coated
plates (NeverWet NuO and I) after 1 hour of thermal exposure at 550, 600 and 700 F

NeverWet-NuO

NeverWet-I

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Simple and Complex Shapes can be Coated

Mounting Hole

Large Test Specimen

Anti-slip Surface

Condenser Section of Steam Turbine Section June 2011

Overhead Transmission Cable 38

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Other Attributes
Ross SH coating can
produce filtration screens where gases can pass through, but not water or other aqueous liquids

Coated Screen Technology is Confidential & Proprietary

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Other Attributes
Mud testing with aluminum plate coated with
Ross SH coating

Dipped in Mud

Uncoated

Coated

Note: No mud sticks to coated side of plate.

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Other Attributes
NeverWet Coatings have Proven Durable through a
Variety of Tests:
Salt-fog testing (>2500 hours) Saltwater submersion (>400 days) Aqueous solutions of acids, alkalis and salts (up to 50%) Extreme temperatures (>1 year at 450F and transients of 550F) Bending (>120 degree bend after 400F thermal cycle) Drag reduction testing (30% drag reduction for <10 ft/s) Taber Minimum 500 tabers for 25 micron coating Minimum 1100 tabers for 50 micron coating Minimum 2000 tabers for 75 micron coating

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Equipment at Ross

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Equipment at Ross
Salt fog testing

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Existing Applications/Trials
Industrial applications
Electronics (computers / laptops / cell phones) Electrical switches Motors Power transmission lines Packaging Food processing Commercial/industrial buildings Fabrics Automotive Aviation Others
June 2011

Medical/Anti-bacterial
applications
Catheters Bedpans Dentistry products Mirrors Hospital equipment Others

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Existing Applications/Trials
Military applications
Clothing Tentage Missiles Aviation Others Refrigerators Plungers Clothing Outdoor furniture Others
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Other applications
Self-cleaning buildings Bridges Many others

Consumer applications

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Summary
Ross Technology has Developed High Durability

Superhydrophobic and Oleophobic Coatings Several Applications have been Tested We Look Forward to Customer Feedback and Questions

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Thank you for your Time & Consideration

Contact Information: 717-207-8155 866-383-7066 For more information, please contact us info@neverwet.com

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